Method and system for screen attachment

ABSTRACT

Methods and apparatus for a display system include a frame and one or more screen panels. Each panel has an inwardly disposed face and an outwardly disposed face. An adhesive layer couples to respective portions of each inwardly disposed face. At least one of the adhesive layers couples the one or more screen panels to the frame.

TECHNICAL FIELD

This invention relates in general to display systems and, in particular,to display systems having an enhanced screen attachment.

OVERVIEW

Television display systems typically include a wide bezel disposed infront of the viewing screen to facilitate mechanical fastening of thescreen. This visible bezel, usually made of plastic or metal, is oftenunattractive to viewers. Minimizing or eliminating the visible bezelwithout compromising reliability is difficult for a variety of reasons.

SUMMARY OF THE EXAMPLE EMBODIMENTS

In one embodiment, an apparatus for a display system includes a frameand one or more screen panels. Each panel has an inwardly disposed faceand an outwardly disposed face. An adhesive layer couples to respectiveportions of each inwardly disposed face. At least one of the adhesivelayers couples the one or more screen panels to the frame.

In a method embodiment, a method of displaying an image includesproviding one or more screen panels of a display system. Each screenpanel has an inward face and an outward face. The outward face isopposite the inward face and disposed closest to a viewing side of thedisplay system. The method further includes coupling an adhesive layerto respective at least a portion of each of each inward face of one ormore screen panels. At least one adhesive layer couples the one or morescreen panels to a frame.

Technical advantages of some embodiments of the disclosure may include adisplay system having an enhanced screen panel attachment with little orno visible bezel. Some embodiments may reduce material and productioncosts compared to conventional mechanical attachment methods.

It will be understood that the various embodiments of the disclosure mayinclude some, all, or none of the enumerated technical advantages. Inaddition other technical advantages of the disclosure may be readilyapparent to one skilled in the art from the figures, description, andclaims included herein.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the disclosure and features andadvantages thereof, reference is now made to the following description,taken in conjunction with the accompanying drawings, in which:

FIG. 1 is an exploded block diagram of a portion of a display system inaccordance with a particular embodiment of the present disclosure;

FIG. 2 is a cross-sectional view illustrating one embodiment of aportion of the display system of FIG. 1 having a bonded pair of screenpanels adhered to a frame; and

FIG. 3 is a cross-sectional view illustrating one embodiment of aportion of the display system of FIG. 1 having two screen panels, eachrespectively adhered to a frame.

DESCRIPTION OF EXAMPLE EMBODIMENTS

In accordance with the teachings of the disclosure, a screen attachmentsystem and method for the same are provided. By coupling screen panelsto a frame using adhesive layers, particular embodiments of the presentdisclosure may minimize or even eliminate the frame bezel, therebyenhancing aesthetics of a visual display system. Particular examples anddimensions specified throughout this document are intended for examplepurposes only, and are not intended to limit the scope of the presentdisclosure. In particular, this document is not intended to be limitedto a particular visible display, such as, a rear projection television.Moreover, the illustrations in FIGS. 1 through 3 are not necessarilydrawn to scale.

FIG. 1 is an exploded block diagram of a portion of a display system 100in accordance with a particular embodiment of the present disclosure. Asshown in FIG. 1, display system 100 generally includes a plurality ofadhesive layers 102 coupling respective screen panels 104 to a frame106. The frame 106 couples screen panels 104 to a chassis 108. Displaysystem 100 is generally capable of producing a visible display bydirecting light source beams (e.g., light beam 110 from light source112) toward screen panels 106.

Adhesive layers 102 generally refer to any adhesive fastener operable tocouple screen panels 104 together and/or couple screen panels 104 toframe 106. In various embodiments, adhesive layers 102 may include, forexample, tape, epoxy, and/or sonic welds. In this particular embodiment,adhesive layers 102 a and 102 b are double-sided tape having acrylicadhesive on both sides of conformable foam. The foam may be viscoelasticin nature to provide tape 102 with energy absorbing and stress relaxingproperties.

In various embodiments, such foam may enhance bond strength betweenscreen panels 104 a, 104 b, and frames 106 made of material that mayhave differing coefficients of thermal expansion. The acrylic adhesiveon each side of the double-sided tape 102 a and 102 b may be selected tooptimally adhere to the respective surfaces of screen panels 104 a, 104b, or frame 106. Tape 102 that offers sealing properties and durableperformance may further enhance display system 100 reliability. Someembodiments may utilize tape 102 having a dark or black appearance toenhance the aesthetics of display system 100. In various embodiments,tape 102 such as 3M™ VHB™ 4941 and 5952 that are approximately 0.045inches thick and 0.25 inches wide may be configured to adequatelyexhibit the above properties; however, other appropriate dimensions orproducts may be used. For example, various other embodiments may usetape with a higher bond strength that facilitates the use of narrowerdimensions.

Various other embodiments may alternatively use an epoxy for adhesivelayers 102, such as, for example, glue or ultraviolet-cured epoxy. Insuch embodiments, the bond strength of various epoxies may facilitate anadhesive layer narrower than 0.25 inches. However, some epoxy adhesivelayers 102 may not exhibit the same thermal-stress relaxing propertiesas the tape adhesive layers 102 previously described. In addition, theedges of some epoxy adhesive layers 102 may not be as aestheticallyuniform as the tape adhesive layers 102 previously described. As shownin the example embodiment of FIG. 1, adhesive layers 102 a and 102 b aredisposed along the edge of the inward surfaces of screen panels 104 aand 104 b respectively.

Screen panels 104 generally refer to any layer or surface for displayingor projecting light, such as, for example, transparent acrylic,polycarbonate plastic, and/or glass. In this particular embodiment,screen panels 104 include a fresnel layer 104 a and a lenticular layer104 b. As explained further below, lenticular layer 104 b steersincident light beams in a direction normal to fresnel layer 104 a.Fresnel layer 104 a has properties that enable a wider viewing angle fordisplay system 100.

Frame 106 generally refers to any structure operable to couple screenpanels 104 to chassis 108. Although FIG. 1 illustrates frame 106 andchassis 108 as distinct pieces, in various other embodiments frame 106may be a solid extension of chassis 108. In the example embodiment,frame 106 is formed from polycarbonate oracrylonitrile-butadiene-styrene(ABS); however, any suitable material maybe used. Chassis 108 generally refers to any casing operable to housethe remainder of components for display system 100, including lightsource 112 and associated optics (not explicitly shown).

Conventional television display systems typically include a wide bezeldisposed in front of the viewing screen to facilitate a strongmechanical holding. The bezel, usually made of plastic or metal, isoften unattractive to viewers. Accordingly, some particular embodimentsof the present disclosure recognize that coupling screen panels 104 tovarious frame 106 designs using adhesive layers 102 may minimize or eveneliminate the front bezel of frame 106, thereby enhancing aesthetics ofa visual display system. Display system designs associated with thesegeneralized example embodiments are further illustrated in FIGS. 2 and3.

FIG. 2 is a cross-sectional view illustrating one embodiment of aportion of the display system 100 of FIG. 1 having a bonded pair ofscreen panels 104 a and 104 b adhered to a frame 106. As illustrated inFIG. 2, adhesive layer 102 a couples together screen panels 104 a and104 b by bonding the inward surface of screen panel 104 a to the outwardsurface of screen panel 104 b. Adhesive layer 102 b couples the pairedscreen panels 104 to frame 106 by bonding the inward surface of screenpanel 104 b to a hidden bezel 114 of frame 106.

In this particular embodiment, a beveled edge 116 of hidden bezel 114allows high-angle light beams 110 to illuminate screen panels 104,including a fresnel layer layer 104 a and a lenticular layer 104 b.Lenticular layer 104 b steers incident light beams (e.g., light beams110) in a direction normal to fresnel layer 104 a. As illustrated inFIG. 2, high-angle light beams 110 pass through lenticular layer 104 bapproximately 0.28 inches from the inner edge of the frame 106 sidewall,in the illustrated embodiment.

In various embodiments, frame 106 and chassis 108 may each respectivelyinclude multiple pieces coupled together. For example, in thisparticular embodiment, frame 106 includes a first portion 106 a thatcovers the sides of screen panels 104 and facilitates screen panel 104attachment. In addition, frame 106 includes a second portion 106 b thatfacilitates the attachment of frame 106 to a second portion 108 b ofchassis 108. A first portion 108 a of chassis 108 b forms an outer shellaround chassis 108. As illustrated in FIG. 2, first and second portions106 a and 106 b of frame 106 and first and second portions 108 a and 108b of chassis 108 may be distinct pieces of display system 100 that arecoupled together. However, the form and structure of frame 106 andchassis 108 may be effected by any of a variety of designs. For example,in various other embodiments first and second portions 106 a and 106 bof frame 106 may be one solid piece and first and second portions 108 aand 108 b of chassis 108 may be another solid piece.

In various embodiments, the gaps between screen panels 104 a and 104 b,frame 106, and chassis 108 may relieve stress associated with thermalexpansion. In some embodiments, these gaps may be minimized by selectingmaterials having coefficients of thermal expansion that are more closelymatched.

The width of adhesive layers 102 a and 102 b may be narrower in variousother embodiments. For example, other embodiments may use strongeradhesives. In such embodiments, hidden bezel 114 of frame 106 may beshorter, thereby enabling increased illumination along the edges ofscreen panels 104. However, in some embodiments, a greater bond isachievable between screen panels 104 and frame 106 than between screenpanel 104 a and screen panel 104 b. Various display system 100 designsmay accommodate the adhering of each screen panel 104 a and 104 b toframe 106. An example embodiment is illustrated in FIG. 3.

FIG. 3 is a cross-sectional view illustrating another embodiment of aportion of the display system 100 of FIG. 1 having two screen panels 104a and 104 b, each respectively adhered to a frame 106. As shown in FIG.3, frame 106 includes a stair-stepped hidden bezel 114. Each step ofhidden bezel 114 provides a bonding surface for a respective screenpanel 104 a and 104 b.

In this particular embodiment, a beveled edge 116 of hidden bezel 114allows high-angle light beams 110 to illuminate screen panels 104,including a fresnel layer layer 104 a and a lenticular layer 104 b.Lenticular layer 104 b steers incident light beams (e.g., light beams110) in a direction normal to fresnel layer 104 a. As illustrated inFIG. 3, high-angle light beams 110 pass through lenticular layer 104 bapproximately 0.5 inches from the inner edge of the frame 106 sidewall.

Although the example embodiments illustrated in FIGS. 2 and 3 do notinclude a bezel disposed outwardly from the screen, other embodimentsmay alternatively include such a visible bezel without departing fromthe scope of the present disclosure.

Although the disclosure has been described in several embodiments, amyriad of changes, variations, alterations, transformations, andmodifications may be suggested to one skilled in the art, and it isintended that the present disclosure encompass such changes, variations,alterations, transformations, and modifications as falling within thespirit and scope of the appended claims.

1. A display system comprising: a chassis; a light source disposedwithin the chassis; one or more screen panels, each screen panel havingan inward face and an outward face, the inward face opposite the outwardface and disposed closer to the light source than the outward face; aframe coupled to the chassis; and an adhesive layer coupled torespective portions of each inward face of the one or more screenpanels, at least one adhesive layer coupling the one or more screenpanels to the frame.
 2. The display system of claim 1, wherein the oneor more screen panels comprises a fresnel layer and a lenticular layer,the fresnel layer disposed inwardly from the lenticular layer.
 3. Thedisplay system of claim 1, wherein the frame is devoid of a bezeldisposed outwardly from the outermost screen panel of the one or morescreen panels.
 4. The display system of claim 1, wherein the frame has asubstantially rectangular bezel disposed outwardly from the outward faceof the outermost screen panel of the one or more screen panels, thebezel width extending no further than twelve millimeters across theoutward face of the outermost screen panel of the one or more screenpanels.
 5. The display system of claim 1, wherein the one or more screenpanels is selected from the group consisting of: glass; and plastic. 6.The display system of claim 1, and further comprising optics andelectronics disposed within the chassis, the optics and electronicsoperable to produce an image that is visible outwardly from an outermostscreen panel of the one or more screen panels.
 7. The display system ofclaim 6, wherein at least a portion of one or more of the adhesivelayers is visible from at least one position where the produced image isvisible.
 8. The display system of claim 7, wherein the at least aportion of the one or more of the adhesive layers appears substantiallyblack.
 9. The display system of claim 1, wherein the adhesive layer isselected from the group consisting of: one or more epoxy layers; and oneor more tape layers.
 10. The display system of claim 9, wherein the oneor more tape layers comprises a double-sided tape layer.
 11. The displaysystem of claim 10, wherein the one or more type layers comprises foamtape.
 12. The display system of claim 9, wherein the one or more epoxylayers comprises a ultraviolet light cured epoxy.
 13. A method ofdisplaying an image comprising: providing one or more screen panels of adisplay system, each screen panel having an inward face and an outwardface, the outward face opposite the inward face and disposed closest toa viewing side of the display system; and coupling an adhesive layer torespective at least a portion of each of each inward face of one or morescreen panels, at least one adhesive layer coupling the one or morescreen panels to a frame.
 14. The method of claim 13, and furthercomprising positioning no portion of the frame outwardly from the outerface of the outermost layer of the one or more screen panels.
 15. Themethod of claim 13, and further comprising providing the frame with asubstantially rectangular bezel disposed outwardly from the outward faceof an outermost screen panel of the one or more screen panels, the bezelwidth extending no further than twelve millimeters across the outwardface of the outermost screen panel of the one or more screen panels. 16.The method of claim 13, and further comprising absorbing a substantialportion of light that is incident to at least a portion of the one ormore of the adhesive layers.
 17. The method of claim 13, and furthercomprising adhering, by the respectively coupled adhesive layer, each ofthe one or more screen panels directly to the frame.
 18. The method ofclaim 13, and further comprising: adhering a lenticular layer of the oneor more screen panels to a fresnel layer of the one or more screenpanels; and wherein the at least one adhesive layer couples the fresnellayer to the frame.
 19. The method of claim 13, and further comprisingbeveling at least a portion of the frame such that more of the outersurface of an outermost screen panel of the one or more screen panelsmay receive light from an inward direction.
 20. A display systemcomprising: a frame; one or more screen panels, each panel having aninwardly disposed face and an outwardly disposed face; and an adhesivelayer coupled to respective portions of each inwardly disposed face, atleast one adhesive layer coupling the one or more screen panels to theframe.